so im building a dana 60 rear end that came out of a 75 f250, i talked with a rep from seven springs custom where i was trying to order a spool that i could run my stock 4.10s and 30 spline axle, which was discontinued. so instead i figured i would upgrade my axles to 35 spline. come to find out after i already installed the spool and everything that my yukon axle shafts are 1/8" to big, now im not sure but i have seen on a few websites that people lath out a section so their upgraded axles fit. i didnt realize i would have these issues until now where im at a stand still any help would be greatly appreciated!! thanks

You need to boar the spindle's open to accept the larger axle's. But becarful some spindle's cant be board. this is whay alot of peaple skip any 60 rears. But dont dispair you can cut the small boar spindle's off ( if there small boar's ) and weld on 14 bolt spindle's. Or junk the axle and find a HD 60 rear or a 60U, bolth of those will have large boar spindles, so the 35 spline shafts will slide threw.

according to the tags the tags and the markings inside, i believe it is a heavy duty 60. can u buy just the 14 bolt spindles or do i have to cut them off any axle, also if i do that can i still run my brake setup or do i need to run the 14 bolt setup....

Should say 60HD on the outside web. If it does then its a odd ball axle. But a 60U will have the large boar spindle's.
And yes you have to chop the spindle off the axle, get a line up bar, remove the full spool, slide the line up bar threw, weld on new spindle's and get larger hub's to mate to the larger spindle's.

Its tuff to say I never done it. But i would have to guess that whatever spindle's you will buy should fit the ID of the tube. Thats somthing you have to contact 4wdfactory and ask them. I would assume a line up bar might be needed.
I use a chunk of 1.5" chrome rod. I use it for when i narrow fronts but with a front you use a combo of the factory tube when you slide the OEM C back on and the inner spindle bearings.

For a rear i would assume the after market spindle's are pressed in and then just welded. Were to cut them, i dont think there welded on i think there formed when hot and then machinend.

ya the dont look welded but i would hate to start beating the crap out of them and end up destroying something

Is a dana 70 the same as a d60, i know the d70 come with 35 spline so the spindles would defly be big enough, but im wondering if the carriers are the same size??

Carriers are different since the 70 use's a 10.5" ring and the 60 use's a 9 3/4" ring. What I would do is go to the junkyard find a early to mid 90's E-250 van with a FF rear axle and check to see if its a dana 60U. This way you can re-use the gears and spool.
The shaft if there the "cut to length your self shafts" from yukon will still work and will go threw the 60U broars. Thats probally the cheapest way out of that axle or sell it all and get a 70 or 14 bolt.

I know its not really the answer your looking for but that year 60 limits you very fast when it come's to upgraded shafts. Search my name and you will see me the same thing over and over about that year axle.

im just trying to find the cheapest fix of my problem with useing the parts i already have.

whats the U stand for in the 60U

The U model means it has a smoth bottom, like a dana 70 has a U model along with the 60U. Now theres a 60HD a dana 61, a dana 70HD, U and a normall ( non HD 60 and 70 ).

The 60U's will have 32 spline shafts but they will have the big boar spindle's so the 35 spline 1.5" shafts will slide threw. This probally the easyest solution to the problem you have since you have all the parts for a 60. Unless you can sell it or send it back and get out of this axle.

Yes they are and most from a mid 90's are FF. Best thing to do is look for the smooth bottom, then pull the shaft messure the boar. This way you can verifie that it will have the right boars and reuse all the 60 stuff.

Good luck and i see your NH, I'm in mass and if i come acroos one i will PM you were i found it and you can pick it up.

just for sh1ts and giggles whats the dodge d60s run for splines and ring gear size??

Dodge can use eather large boar or small boar and i dont know the years they split the two up. I would say If i had to guess the later model years like a mid to late 80's should have the larger boars but really i cant speak for them. I only really know the ford and all of the dana 70 axle's.

If you have one check the boar and see if the shaft will slide threw. If it does then use it.